Textured breast implant and methods of making same

ABSTRACT

Methods for texturing surgical implants, for example, breast implants, are provided. The methods include the use of computer controlled 3D printing of a sacrificial material to create a textured surface on an unfinished surface of the implant.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application a continuation of U.S. patent application Ser. No.14/703,307, filed on May 4, 2015, which claims the benefit of U.S.Provisional Patent Application No. 61/994,767, filed on May 16, 2014,the entirety of each of which is incorporated by reference herein

BACKGROUND

The present invention is generally directed to implantable devices, andis more specifically directed to breast implants and methods forcreating a textured surface on breast implants.

Breast implants are well known for use in breast reconstruction and foraesthetic purposes, for example, to improving the appearance of thebreast. Such implants typically comprise a flexible silicone shell whichmakes up outer surface of the implant. The shell surrounds a siliconegel or saline filling. Many commercially available implants includeso-called “textured surfaces” on the outer surface of the shell. Suchtextured surfaces are purposefully made to interact with the breasttissue in a healthy manner. Among other things, the type of texture mayinfluence tissue ingrowth and reduce the occurrence of capsularcontracture, an adverse event sometimes associated with breast implants.

Several methods for creating a textured surface on an implant currentlyexist. One method is to use a sacrificial material, for example, saltparticles. Salt particles are applied to a silicone shell as the shellis being molded on a mandrel. The particles take up space within thesilicone material as the material is being cured. When the sacrificialmaterial is removed (dissolved, melted, etc.), the shell surface has anegative imprint of the original structure of the particles.

Despite many advances in the construction of breast implants, thereremains a need for better texturing methods. There has been an interestin developing an optimally textured surface that will affect the breasttissue in the healthiest manner.

SUMMARY

The present invention provides improved methods of making texturedsurfaces for breast implants. In one embodiment, a method for creating atextured surface on a breast implant generally comprises providing abreast implant shell, applying a tacky silicone layer on the shell,using a computer-controlled deposit mechanism to deposit a texturingmaterial in a predetermined manner onto the tacky silicone layer andremoving the texturing material from the tacky silicone layer to obtaina textured surface.

The step of using a computer-controlled deposit mechanism may comprisedepositing onto the tacky silicone layer a predetermined number ofsuccessive layers of the texturing material. Further, a binder may beapplied to one or more predetermined regions of each successive layer oftexturing material to cause the texturing material to become bonded atsaid one or more predetermined regions.

In one embodiment, the texturing material is a sugar. The binder may bean aqueous solution or alcohol.

In another embodiment, the method further comprises the step of applyingan additional silicone layer to the deposited layers of texturingmaterial.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention may be more readily understood, and the numerousaspects and advantages thereof better appreciated, with reference to thefollowing Detailed Description and accompanying Drawings of which:

FIGS. 1A-1C illustrates one process for forming flexible implant shellsfor implantable prostheses and tissue expanders;

FIG. 2 is a flow chart illustrating a method in accordance with anembodiment of the invention; and

FIG. 3 is a breast implant made using a method in accordance with anembodiment of the invention.

DETAILED DESCRIPTION

Generally, the present invention provides a breast implant, or othersoft implant, comprising a shell, for example, a silicone elastomershell, with a textured surface, and methods for making such implants andtextured surfaces. One application for such soft implants is forreconstruction or augmentation of the female breast. Other potentialapplications for implants that would benefit from having a texturedsurface are also considered to be within the scope of the invention.

FIGS. 1A-1C illustrates one conventional process for forming flexibleimplant shells, useful as components of the present invention, forimplantable prostheses and tissue expanders. The process typicallyincludes dipping a suitably shaped, e.g. breast implant-shaped, mandrel20 into a liquid elastomer, e.g. a silicone elastomer dispersion 22.This method may make up some of the preliminary steps in accordancecertain embodiments of the invention.

The elastomer dispersion may comprise a silicone elastomer and asolvent. The silicone elastomer may be any suitable biocompatiblesilicone elastomer, for example, polydimethylsiloxane,polydiphenyl-siloxane or some combination of these two elastomers.Typical solvents include xylene or trichloromethane. Differentmanufacturers vary the type and amount of the ingredients in thedispersion, the viscosity of the dispersion and the solid content of thedispersion. Nonetheless, the present invention is expected to beadaptable to have utility with a wide variety of elastomers.

The mandrel 20 is withdrawn from the dispersion and the excess siliconeelastomer dispersion is allowed to drain from the mandrel. After theexcess dispersion has drained from the mandrel, at least a portion ofthe solvent is allowed to volatilize or evaporate. This may beaccomplished by flowing air over the silicone-coated mandrel at acontrolled temperature and humidity. Different manufacturers use variousquantities, velocities or directions of air flow and set the temperatureand humidity of the air at different values. However, the desiredresult, driving off the solvent, remains the same.

The dip and volatilize procedure may be repeated (e.g., repeating of thesteps shown in FIGS. 1B and 1C) a number of times so that a number oflayers of silicone are built up on the mandrel to reach a desired shellthickness. A layered structure can be made by sequentially dipping themandrel in different silicone dispersions. Alternatively, the steps maybe repeated in a single dispersion so that a finished breast implantshell 24, for example, prior to the texturing, filling and finishingsteps, is a single homogenous material or layer. That is, the dippingprocess may be done in multiple stages or steps, each step adding morematerial, yet the shell exhibits no distinct layers and the entire shellwall is homogenous or uniform in composition.

Once the elastomer shell has been stabilized, by allowingvolatilization, any loose fibers or particles may be removed from of theexterior of the shell, for example, with an anti-static air gun.

At this point, a tack coat layer is sometimes applied to the shell inorder to prepare it for a texturing process. The tack coat layer may besprayed on, or may be applied by dipping the flexible shell on themandrel into a tack coat material, for example, silicone elastomerdispersion. The shell is immersed into the elastomer dispersion and themandrel/shell is mounted on a rack for stabilization. The time requiredfor stabilization typically varies between about 5 and about 20 minutes.The tack coat layer may be made using the same material employed in thebase layers.

In some prior art processes for texturing implants, after the tack coatlayer has been applied, solid salt particles are applied to the tackcoat. The solid salt particles are applied by sprinkling particles onthe tack coat, or immersing the tack coated shell/mandrel into afluidized salt particle bath. In this prior art process, the siliconedispersion with salt particles embedded therein, is allowed to stabilizeor cure. The salt particles are then removed by placing the shell in awater bath and rubbing the particles out of the silicone shell, therebyresulting in a textured implant shell, which can be filled with siliconegel or saline, and with some further finalizing steps, is packaged foruse as a breast implant.

In accordance with one aspect of the present invention, rather than anapplication of salt particles to the tack coat as generally describedherein above, some embodiments of the present invention provides methodsof texturing comprising applying a sacrificial material to a tack coatlayer by sequential layering of a material to create a desired form orpattern.

In one embodiment, this is accomplished using a computer to create thedesired form or pattern from the sacrificial material. The desired formor pattern may be created with computer-aided design technology and/orby using a 3D scanning technology to replicate a desired pattern orform.

Processes in accordance with the invention utilize computer aidedmanufacturing technology, commonly referred to as solid freeformfabrication (SFF) or layer manufacturing (LM). A LM process typicallybegins with the representation of a 3-D object using a computer-aideddesign (CAD) model or other digital data input. These digital geometrydata are then converted into machine control and tool path commands thatserve to drive and control a part-building tool (e.g., an extrusion heador inkjet-type print head) that forms the object, layer by layer. LMprocesses are capable of producing a freeform object directly from a CADmodel without part-specific tooling (mold, template, shaping die, etc.)or human intervention.

LM processes were developed primarily for producing models, molds, dies,and prototype parts for industrial applications. In this capacity, LMmanufacturing allows for the relatively inexpensive production ofone-off parts or prototypes, and for subsequent revisions and iterationsfree of additional re-tooling costs and attendant time delays. Further,LM processes are capable of fabricating parts with complex geometry andinteriority that could not be practically produced by traditionalfabrication approaches. This is especially beneficial for the presentinvention, in which complex geometries, and hence complex resultingtextured surfaces, for example, on a micron-sized scale, can be producedwith high precision, in a manner not possible with conventional methodsof texturing.

Examples of LM techniques include stereo lithography (Sla), selectivelaser sintering (SLS), laminated object manufacturing (LOM), fuseddeposition modeling (FDM), laser-assisted welding or cladding, shapedeposition modeling (SDM), and 3-D printing (3-DP). The latter categoryincludes extrusion and binder deposition technologies.

In one aspect of the present invention, sacrificial material may be“printed” onto the silicone surface of the shell using 3D printingtechnology, to form a desired pattern or form, which is then removedfrom the silicone surface to result in a desired surface texture. Insome embodiments, the sacrificial material is applied in a predeterminedpattern using a computer-controlled deposit mechanism, the predeterminedpattern being a model pattern stored in a CAD format.

The sacrificial material may be any suitable material that can be formedon a substrate (e.g. tacky breast implant shell), into a pattern orform, for example, on a micrometer scale, using additive manufacturingtechnologies, and subsequently removed from the substrate to leave anegative imprint in the desired pattern or form.

After the sequential layering of the sacrificial material, thesacrificial material may then be removed, leaving an imprint or negativespace corresponding thereto, for example, cavities and surfacescorresponding to the 3D pattern or form corresponding to the 3D printedsacrificial material.

For example, to perform a print, a machine reads a design from 3Dprintable file (STL file) and lays down successive layers of material tobuild the model from a series of cross sections. These layers, whichcorrespond to the virtual cross sections from the CAD model, are joinedor automatically fused to create the final shape. One primary advantageof this technique is its ability to create almost any shape or geometricfeature. In the breast implant texturing art, this can be especiallyuseful because intricate, well controlled textures, on a micrometerscale, may be created on implant surfaces, for example, textures whichprovide, at a cell-sized level, a desired architecture for controllingcell ingrowth, collagen fiber development and the like.

In some embodiments of the invention, the method uses binder depositionprinting, for example, binder jetting. Such technology may utilizetranslating powder and binder solutions. U.S. Pat. No. 5,340,656, issuedto Sachs et al. describes such a system, the entire disclosure of thisdocument being incorporated herein by this specific reference. Apowder-like material (e.g., powdered ceramic, metal, or plastic) isdeposited in sequential layers, each on top of the previous layer.Following the deposition of each layer of powdered material, a liquidbinder solution is selectively applied, using an ink-jet printingtechnique or the like, to appropriate regions of the layer of powderedmaterial in accordance with a sliced CAD model of the three-dimensionalpart being formed. This binder application fuses the currentcross-section of the part to previously bound cross-sections, andsubsequent sequential application of powder layers and binder solutioncomplete the formation of the desired part.

For example, in embodiments of the present invention utilizing binderdeposition printing technology, the sacrificial material may begin as apowder material which is bonded in layers using a suitable binder. Thebinder may be, for example, any liquid or solution that can be ejectedby ejector parts of a binder deposition printing system, and acts tobind the powder material. Suitable binders may include, but are notlimited to, aqueous solutions, alcohol, or other suitable liquids. Usingbinder deposition technology, the printed, bound material is supportedat all times during the build process by submersion in surroundingunbound material, which facilitates the production of intricate anddelicate geometries. Furthermore, unbound powder can be easily removedand recycled for further use.

For example, the sacrificial material may comprise a sugar. The powdermaterial may comprise a powdered sugar and the binder may comprise asuitable liquid, for example, a starch-containing water. In oneembodiment, the sacrificial material is a sugar that is “printed” ontothe shell using technology described, for example, in Hasseln, U.S.Patent Publication No. 2013/0034633, which is incorporated herein in itsentirety, by this specific reference.

In some embodiments, a system for creating the texture on an implantshell is provided, the system comprising a computer and a textureforming apparatus. The computer may be a general desktop type computeror the like that is constructed to include a CPU, RAM, and others. Thecomputer and texture forming apparatus are electronically connected to acontroller.

The texture forming apparatus is used to create the intricate, patternedor formed sacrificial material on the implant shell, as mentionedelsewhere herein.

For example, a printing stratum is applied to the breast implant shell.The printing stratum may comprise a powdered material, such as apowdered salt, sugar, or other suitable material that can be bound witha suitable binder using deposition printing technology.

The texture forming apparatus includes a 3-D printing apparatus. Theprinting apparatus may include components for moving a carriage along aY-direction and along the X-direction in a plane defined by the X-axisand the Y-axis, as dictated by the controller. The carriage contains abinder cartridge containing binder material, and a binder ejector. Thebinder ejector is connected to the controller. The cartridge part andits associated ejector are components of the carriage, and are freelymovable in the XY-plane. Binder solution is ejected from the ejector andadheres to the specified region(s) of the printing stratum.

Once it has been “printed” onto the shell, the 3D texturing material(sacrificial material) is allowed to set, if needed. It may then beremoved from the shell to leave a texture in the shell, for example, inthe case where the texturing material is applied to a tacky, not fullycured, silicone layer on the shell.

Alternatively, prior to removing the sacrificial material, anelastomeric dispersion can be applied, for example, in a fine layer, tothe printed sacrificial material, and allowed to set or cure.Thereafter, the sacrificial material can be removed by rinsing the shellin water or other solution to cause the material to dissolve frombetween the elastomer shell and upper layer.

Multiple, alternating layers of elastomer and sacrificial material canbe applied to a shell to result in texturing having a desired depth orthickness. An example of a method of the invention using alternativelayering is illustrated in FIG. 2.

Using the present methods, it becomes possible to vary the texture onthe implant in various thicknesses and in various regions of the breastimplant shell. For example, there can be areas of the shell havingtexture, and areas of the shell having essentially no texture, or lesstexture.

Texture pattern may be varied from “front” to “back” sides of implant.In some embodiments, the texture is provided on the front, or anteriorsurface, of the implant, and is reduced or even omitted on the back, orposterior surface, of the implant. In this embodiment, breast tissueadherence may be thus enhanced at the front of the implant and may bereduced on the back of the implant where the implant may contact muscletissue, for example, when the implant is placed subglandularly.

Breast implants may be placed in the breast in one of several differentpositions, depending on desired outcome, and/or patient and surgeonpreference.

In subglandular placement, the breast implant is placed in a surgicallyformed pocket directly between the glandular breast tissue and thepectoralis major muscle. This placement most approximates the plane ofnormal breast tissue. In addition, this placement may offer shortersurgery, less pain and discomfort and perhaps a faster recovery. On thedownside, subglandular placement may result in a more palpable implant,a higher chance of visible rippling or folding of the implant, andhigher risk of capsular contracture.

In submuscular placement, the breast implant is placed beneath thepectoralis major muscle. Thus, the implant is further away from the skinsurface and may be less visible or less palpable. This placement mayappear more “natural” because the implant is further away from the skin.It may require a longer surgery and recovery period, but is believed toresults in a reduced chance for capsular contracture. In breastreconstruction patients where natural breast tissue may be substantiallyor entirely absent, this placement approach effects maximal coverage ofthe implant.

Dual plane breast implant placement is a combination approach in whichthe implant is placed beneath the pectoralis major muscle, after thesurgeon releases the inferior muscular attachments. As a result, theupper portion of the implant is partially beneath the pectoralis majormuscle, while the lower portion of the implant is positioned in thesubglandular plane. This implantation technique may achieve improvedcoverage of the upper portion of the implant and allow filling of minorlaxity of the lower breast.

Accordingly, in some embodiments, the breast implants in accordance withembodiments of the invention, include distinct regions of texturing,some regions including surfaces more conducive to tissue ingrowth, andsome regions including surfaces less conducive to tissue ingrowth.

For example, in some embodiments, an anterior surface of the breastimplant shell, that is, the surface facing the front of the patient'sbody, can have a texture made with the presently described methods, andthe posterior side of the implant shell, that is, the surface facing theback of the patient's body, can have less texture or no texture. Thisembodiment may be most beneficial for subglandular placement of theimplant.

Implant 40, shown in FIG. 3, is an example of an embodiment of theinvention. The implant 40 is made using methods described herein. Asshown, anterior surface 42 of the implant 40 is textured, for example,using 3D printing techniques. Posterior surface 44 of implant 40 has areduced texture (relative to the anterior surface), or no texture, or amatte texture.

Alternative embodiments, (not shown) include the reverse, for example,in that the anterior surface has no texture, reduced texture or mattetexture, and the posterior surface has enhanced texture. Many othervariations of texturing distinct patterns or portions of the implant arecontemplated and the invention is not limited to the specific onesdescribed herein. For example, Van Epps, U.S. Patent Publication No.2013/0261745, describes a dual plane implant with an advantageoussurface pattern especially useful for the dual plane breast implantplacement surgical technique briefly described above. This patentpublication is incorporated herein in its entirety by this specificreference.

The present invention allows for creation of a distinct and precisetexture pattern (such as a close packed hexagonal pattern) which is notavailable using conventional breast implant texturing processes. Theseand other carefully, precisely designed, specific, repeatable texturepatterns may be implemented by the use of 3D CAD files—such as, forexample, closed hexagonals, nested/tangent circles, rectangles.Furthermore, each implant size and geometry can be tailored to fit withthe use of a 3D texturing model both round and ergonomic shapedimplants.

Although the invention has been described and illustrated with a certaindegree of particularity, it is understood that the present disclosurehas been made only by way of example, and that numerous changes in thecombination and arrangement of parts can be resorted to by those skilledin the art without departing from the scope of the invention, ashereinafter claimed.

What is claimed is:
 1. A method for creating a textured breast implant,the method comprising: dipping a mandrel into a liquid elastomer to forma breast implant shell around the mandrel; depositing, via athree-dimensional printing process, a texturing material onto the breastimplant shell to form a first micrometer-scale pattern for creating animprint on the breast implant shell; curing the breast implant shell toform a first cured, imprinted layer; removing the texturing materialfrom the first cured, imprinted layer to form a textured surface;applying a tacky layer onto the textured surface; depositing, viathree-dimensional printing, additional texturing material onto the tackylayer to form a second micrometer-scale pattern for creating a secondimprint on the tacky layer; curing the tacky layer to form a secondcured, imprinted layer; and removing the additional texturing materialfrom the second cured, imprinted layer to obtain a second texturedsurface, the first and second cured, imprinted layers being configuredto permit ingrowth of cells into the breast implant.
 2. The method ofclaim 1, wherein the step of depositing, via a three-dimensionalprinting process, the texturing material onto the breast implant shellcomprises: depositing a predetermined number of successive layers of thetexturing material; and applying to one or more predetermined regions ofeach successive layer of texturing material a binder that will cause thetexturing material to become bonded at said one or more predeterminedregions.
 3. The method of claim 1, wherein the texturing materialcomprises a sugar.
 4. The method of claim 1, wherein the texturingmaterial comprises a sugar and a binder in an aqueous solution oralcohol.
 5. The method of claim 1, further comprising obtaining apredetermined thickness of cured, imprinted layers by applyingadditional alternating layers of a tacky layer and texturing material.6. The method of claim 5, wherein the predetermined thickness varies invarious regions on the textured surface.
 7. The method of claim 1,wherein the first or second micrometer-scale patterns is one of aclosely packed hexagonal pattern, a nested/tangent circle pattern, or arectangle pattern.
 8. The method of claim 1, wherein thethree-dimensional printing process utilizes binder deposition printing.9. The method of claim 1, wherein the removing the texturing materialfrom the first cured, imprinted layer comprises placing the shell in awater bath and rubbing the texturing material from the breast implantshell.
 10. The method of claim 1, wherein the removing the additionaltexturing material from the second cured, imprinted layer comprisesplacing the shell in a water bath and rubbing the additional texturingmaterial from the tacky layer.
 11. A method for creating a texturedbreast implant having a plurality of textured layers thereon, methodcomprising repeatedly, for each textured layer, performing the steps of:applying a tacky layer onto the implant; depositing, via athree-dimensional printing process, a texturing material in apredetermined pattern onto the tacky layer of the implant; curing thetacky layer; and removing the texturing material from the tacky layer toobtain a textured layer.
 12. The method of claim 11, further comprisingobtaining a predetermined thickness of the textured layer by applyingthe tacky layer and the texturing material alternately.
 13. The methodof claim 12, wherein the predetermined thickness varies in variousregions on the textured layer.
 14. The method of claim 11, wherein thetexturing material comprises a sugar.
 15. The method of claim 11,wherein the predetermined pattern comprises a micrometer-scale patternof a hexagonal pattern, a circle pattern, or a rectangle pattern.
 16. Amethod for creating a textured breast implant, the method comprising:dipping a mandrel into a liquid elastomer to form a breast implant shellaround the mandrel; forming a first micrometer-scale pattern on thebreast implant shell using sugar and a solid freeform fabrication (SFF)or layer manufacturing (LM) technique; curing the breast implant shellto form a first cured, imprinted surface; removing the sugar from thefirst cured, imprinted surface; after removing the sugar from the firstcured, imprinted surface, applying a tacky layer onto the first cured,imprinted surface; forming a second micrometer-scale pattern on thetacky layer using sugar and a solid freeform fabrication (SFF) or layermanufacturing (LM) technique; curing the tacky layer to form a secondcured, imprinted surface; and removing the sugar from the second cured,imprinted surface to obtain a second textured surface that facilitatescell ingrowth on the implant.
 17. The method of claim 16, wherein thesugar is applied in a liquid binder solution comprising an aqueoussolution or alcohol.
 18. The method of claim 16, wherein the removingthe sugar from the first cured, imprinted surface comprises placing theshell in a water bath and rubbing the sugar from the first cured,imprinted surface.
 19. The method of claim 16, wherein the removing thesugar from the second cured, imprinted surface comprises placing theshell in a water bath and rubbing the sugar from the second cured,imprinted surface.
 20. The method of claim 16, wherein the breastimplant shell comprises silicone.